Double molded product

Abstract: A double molded product is produced by secondary molding a primary molded product with a resin, the primary molded product comprising, a connector portion accommodating at least one wire, and an inside-outside communication portion communicating the inside of a mold with outside during a secondary molding. The inside-outside communication portion comprises, at least one notch for respectively holding the wires extending form inside of the mold to the out side.

Description: This invention relates to a double moulded product, and more particularly to a double moulded product in which wires are mounted on a primary moulded product, and then a resin is moulded on this primary moulded product. DE-A-41 30 603 shows a holder for round flexible wires having stress relieve means. The holder is in form of a casing being constituted by two casing halves. One half has protruding bifurcated holding tongues for receiving the cables at part of a periphery thereof and the other half has pressing means for intruding between two adjacent cantilevers of two adjacent holding tongues in order to press them apart and so all pressing means simultaneously press the cantilevers of all holding tongues together with the respective wires therebetween. DE-U-87 02 058 shows a connector for a wire harness of an automobile. The connector is constituted by two halves, which are connected by a hinge portion. The harness is led into one half of the opened connector, is spread and led into individual contact portions. After this, the two connector halves are closed and by doing so, the individual wires of the wire harness are fixed in place. However, both in DE-A-41 30 603 and DE-U-87 02 058 the wires are held or clamped mechanically and not by a moulding operation. A conventional double moulded product is disclosed in EP-A-0 519 709 corresponding to JP-A-4 369 515. What is disclosed is a double moulded connector. As shown in Figs. 6 and 7 of the accompanying drawings, a connector portion 1a for holding wires 3, which has a fitting terminal 2 clamped to a front end thereof, is formed at an upper portion of a primary moulded product 1. An inside-outside communication portion 1b for communicating the inside of a mould with the outside of the mould during a double moulding operation is formed at a lower portion of the primary moulded product. The inside-outside communication portion 1b has through holes 1b1 for the passage of the wires 3 therethrough, respectively. For producing the connector of such a construction, the fitting terminal 2 is compressively clamped to one end of the wire 3, and this end portion is held by the connector portion 1a, and the other end of the wire 3 is passed through the through hole 1b1 in the inside-outside communication portion 1b. Then, the connector portion 1a is placed in moulds, with the inside-outside communication portion 1b held between the moulds. After a resin moulding, a double moulded product 4 is completed as shown in Figs. 8 and 9. Thus, the primary moulded product is held between the moulds, with each wire 3 passed through the through hole 1b1 in the inside-outside communication portion 1b. By doing so, the moulds will not be contacted directly with the wires, and the wires will not be clamped between the moulds, and a covering of the wire will not be fused. In the above conventional double moulded product, it is necessary to pass one end of the wire through the through hole in the inside-outside communication portion, and this through hole has a diameter substantially equal to that of the wire so that any leakage will not occur during a double moulding operation. Therefore, there has been encountered a problem that much time and troublesome work are required for passing the wire. The present invention has been made in view of the above problem encountered with the conventional double moulded product as disclosed in EP-A-0 519 709, and an object of the invention is to provide a double moulded product which can reduce time and troublesome work required in process. In order to achieve the above object, the invention provides a double moulded product which is produced by secondary moulding a primary moulded product with a resin, said primary moulded product comprising: a connector portion accommodating at least one wire; an inside-outside communication portion communicating the inside of a mould with the outside during said secondary moulding, said inside-outside conununication portion comprising at least one notch for respectively accomodating the wire extending from the inside of said mould to the outside; and a lid portion for closing said notch, with the wire held respectively in said notch, said double moulded product being furthermore characterized in that said notch includes a wire retaining portion for retaining the wire at an inner end portion of said notch, and said lid comprising at least one holder piece corresponding respectively to said at least one notch and being receivable therein, the width of said at least one holder piece being equal to the width of said at least one notch and the distal end of said at least one holder piece being recessed into a semi-circular shape corresponding to a semi-circular shape of the inner end portion of said at least one notch such that when the distal end of said holder piece and the inner end of said notch are disposed in facing relation to each other, they jointly form a cylindrical hole surrounding the periphery of said wire sealingly. Each wire is pushed into its corresponding notch in a direction perpendicular to the axis of the wire. After the wire is thus pushed into the notch, the lid portion is moved so that the holder pieces can be inserted into the notches, respectively. As the holder pieces are inserted, they press the respective wires at their distal ends deeper toward the inner ends of the notches. The semi-circular surface of the inner end of each of the notches and the semicircular surface of the distal end of a respective one of the holder pieces surround the periphery of the wire W. Thereafter, the connector portion is placed in the mould for double moulding purposes in such a manner that the inside-outside communication portion communicates the inside of the mould with the outside of the mould, and a resin is filled in the mould, thus completing a double moulding operation. At this time, because the cylindrical holes, which are formed by facing the notches and the holder pieces, are sealed with the wires, the resin does not leak through the inside-outside communication portion. This invention will be more readily understood from the following description thereof, which is to be seen in conjunction with the accompanying drawings, in which: Fig. 1 is a perspective view of a core of a double moulded product in the form of a connector provided in accordance with the present invention; Fig. 2 is a perspective view of the core having a wire mounted thereon; Fig. 3 is a cross-sectional view of an inside-outside communication portion; Fig. 4 is a perspective view of another embodiment of a core; Fig. 5 is a cross-sectional view of an inside-outside communication portion of another embodiment; Fig. 6 is a perspective view of a conventional core having a wire mounted thereon; Fig. 7 is a cross-sectional view of the conventional core having the wire mounted thereon; Fig. 8 is a perspective view showing a double moulded condition; and Fig. 9 is a cross-sectional view showing the double moulded condition. A preferred embodiment of the present invention will now be described with reference to the drawings. Fig. 1 is a perspective view of a primary moulded product (hereinafter referred to as "core") of a double moulded product in the form of a connector according to the present invention. In this Figure, a connector portion 11 is formed at an upper portion of the core 10, and an inside-outside communication portion 12 for communicating the inside of a mould with the outside of the mould during a double moulding operation is formed at a lower portion of the core. The inside-outside communication portion 12 includes a body portion 12a in the form of a generally rectangular block, and a lid portion 12c connected through a hinge portion 12b shaped a thin sheet to the body portion 12a for being able to turn into facing relation to one side face of the body portion 12a. Four notches 12a1 ~ 12a4 are formed in that side face of the body portion to which the lid portion 12c can be turned into facing relation, and extend from an upper face to a lower face of the body portion. An inner end of each of the notches 12a1 ~ 12a4 has a semi-circular shape, and the diameter of this semi-circular portion is equal to that of a wire W. Holder pieces 12c1 ~ 12c4 corresponding respectively to the notches 12a1 ~ 12a4 are formed on and projected from that side of the lid portion 12c which can be turned into facing relation to the body portion 12a, the holder pieces 12c1 ~ 12c4 being receivable in the notches 12a1 ~ 12a4, respectively. The width of the holder pieces 12c1 ~ 12c4 is equal to the width of the notches 12a1 ~ 12a4, and the distal end of each holding piece is recessed into a semi-circular shape corresponding to the semi-circular shape of the inner end of each notch 12a1 ~ 12a4. With this arrangement, when the distal end of each holding piece and the inner end of the corresponding notch are disposed in facing relation to each other, they jointly form a cylindrical hole. Projections 12d1 and 12d2 are formed respectively on opposite end portions of that side of the lid portion 12c having the holder pieces 12c1 ~ 12c4 formed thereon. Engagement holes 12e1 and 12e2 are formed respectively on opposite end portions of that face of the body portion 12a having the notches 12a1 ~ 12a4 formed therein, and are arranged respectively at positions corresponding to the projections 12d1 and 12d2, respectively. The wire W, as well as a fitting terminal T compressively clamped to a front end of the wire W, is the same as a conventional one. The operation for producing the connector which is described above will now be described. First, the fitting terminal T is compressively clamped to one end of the wire W, and is held by the connector portion 11, as in the conventional construction. After the end portion of the wire with the fitting terminal T clamped thereto is thus held, each wire W is bent to be directed to an open end of a respective one of the four notches 12a1 ~ 12a4. Each wire W is pushed into this notch in a direction perpendicular to the axis of the wire W. After the wire is thus pushed into the notch, the hinge portion 12b is bent to turn the lid portion 12c so that the holder pieces 12c1 ~ 12c4 can be inserted into the notches 12a1 ~ 12a4, respectively. This condition is shown in Fig. 2. As the holder pieces 12c1 ~ 12c4 are inserted, they press the respective wires W at their distal ends deeper toward the inner ends of the notches 12a1 ~ 12a4, respectively. When the projections 12d1 and 12d2 on the lid portion 12c are fitted respectively into the engagement holes 12e1 and 12e2 in the body portion 12a, the semi-circular surface of the inner end of each of the notches 12a1 ~ 12a4 and the semicircular surface of the distal end of a respective one of the holder pieces 12c1 ~ 12c4 surround the periphery of the wire W. Thereafter, the connector portion 11 is placed in the mould for double moulding purposes in such a manner that the inside-outside communication portion 12 communicates the inside of the mould with the outside of the mould, and a resin is filled in the mould, thus completing a double moulding operation. At this time, because the cylindrical holes, which are formed by facing the notches and the holder pieces, are sealed with the wires W, the resin does not leak through the inside-outside communication portion 12. When the mould is removed after the resin is solidified, there is provided the connector as shown in Fig. 8. Thus, the notches 12a1 ~ 12a4 are formed in the inside-outside communication portion 12 adapted to extend from the inside of the mould to the outside of the mould, and merely by pushing the wires W into these notches 12a1 ~ 12a4, respectively, the wires W can be mounted in a manner to extend from the inside of the mould to the outside of the mould, without being contacted with the mould. The open ends of the notches 12a1 ~ 12a4 are closed by the lid portion 12c, and therefore the wire W once pushed into the notch 12a1 ~ 12a4 will not be disengaged therefrom. In the above embodiment, although the lid portion 12c is integrally connected to the body portion 12a through the hinge portion 12b, they may be separate from each other, as shown in Fig. 4. Although the notches 12a1 ~ 12a4 have a U-shaped cross-section having generally parallel opposed side surfaces as shown in Fig. 3, they may be of such a configuration that opposed side surfaces 12f1 and 12f2 get closer to each other progressively toward the inner end to gradually reduce the width, and that a wire holder groove 12f3 of a generally circular shape is formed at the inner end, as shown in Fig. 5. In this case, the distance between the side surfaces 12f1 and 12f2 at an open portion of the wire holder groove 12f3 is smaller than the diameter of the wire W, and therefore the wire W forced into the wire holder groove 12f3 is prevented from being disengaged therefrom. Namely, those portions from the inner end of the side surfaces 12f1 and 12f2 to the wire holder groove 12f3 serve as a wire retaining portion for retaining the wire at the inner end of the notch. And therefore even without the lid portion 12c, the wire W would not be disengaged. Even if the lid portion 12c is not provided, the wire can be held in the notch in such a manner that the wire extends from the inside of the mould to the outside of the mould.

Claims: A double moulded product which is produced by secondary moulding a primary moulded product with a resin, said primary moulded product comprising: a connector portion (11) accommodating at least one wire (W); an inside-outside communication portion (12) communicating the inside of a mould with the outside during said secondary moulding, said inside-outside communication portion (12) comprising at least one notch (12a1 ~ 12a4) for respectively accomodating the wire (W) extending from the inside of said mould to the outside; and a lid portion (12c) for closing said notch (12a1 ~ 12a4), with the wire (W) held respectively in said notch (12a1 ~ 12a4), characterized in that said notch (12a1 ~ 12a4) includes a wire retaining portion for retaining the wire at an inner end portion of said notch (12a1 ~ 12a4), and said lid (12c) comprising at least one holder piece (12c1 ~ 12c4) corresponding respectively to said at least one notch (12a1 ~ 12a4) and being receivable therein, the width of said at least one holder piece (12c1 ~ 12c4) being equal to the width of said at least one notch (12a1 ~ 12a4) and the distal end of said at least one holder piece (12c1 ~ 12c4) being recessed into a semi-circular shape corresponding to a semi-circular shape of the inner end portion of said at least one notch (12a1 ~ 12a4) such that when the distal end of said holder piece (12c1 ~ 12c4) and the inner end of said notch (12a1 ~ 12a4) are disposed in facing relation to each other, they jointly form a cylindrical hole surrounding the periphery of said wire (W) sealingly. The double moulded product according to claim 1, wherein a plurality of notches (12a1 ~ 12a4) is provided in said connector portion (11) and a corresponding plurality of holder pieces (12c1 ~ 12c4) is provided in said lid (12c) for holding a plurality of wires (W). The double moulded product according to claim 2, wherein said notches (12a1 ~ 12a4) are tapered such that opposed side surfaces (12f1, 12f2) thereof getting closer to each other progressively toward the inner end to gradually reduce the width and said holder pieces (12c1 ~ 12c4) are tapered such that opposed side surfaces thereof getting closer to each other progressively toward the distal end thereof. The double moulded product according to claim 3, wherein the inner ends of said notches (12a1 ~ 12a4) open into a cylindrical wire holder groove (12f3).

Inventors: ITO KATSUYA, ITO, KATSUYA, ITO, KATSUYA, C/O SUMITOMO WIRING SYSTEMS, LTD.
Applicants: SUMITOMO WIRING SYSTEMS, SUMITOMO WIRING SYSTEMS, LTD.
Application year: 1994
Main classification: H01R13
IPC codes: H01R13, B29C45, B29L31, B29K105